Electrolytic hydrogen generating system

ABSTRACT

A hydrogen generating system includes a plurality of conductive plates, a first connector and a second connector, wherein each connector is connected to at least some of the plates, an amperage sensor configured to measure an actual amperage of the hydrogen generating system, and a temperature sensor configured to measure an actual temperature of the hydrogen generating system, and a controller. The controller includes a processor programmed to receive a target amperage, a maximum amperage threshold, a maximum temperature threshold, and an optimal temperature, select, based on the target amperage, certain of the plurality of conductive plates to receive an applied voltage, receive a measurement of an actual amperage and an actual temperature from the amperage sensor and the temperature sensor, respectively, compare the actual amperage and the actual temperature to the maximum amperage threshold and the optimum temperature, respectively, and adjust the applied voltage based on the comparison.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 61/115,463 filed on Nov. 17, 2008 and 61/117,481 filedon Nov. 24, 2008, respectively, both of which are hereby incorporated byreference in their entirety.

BACKGROUND

The use of hydrogen and oxygen gas to supplement the conventional fuelin an internal combustion engine in order to increase the efficiency ofthe engine is known. For example, electrolytic hydrogen generatingsystems are known to produce hydrogen and oxygen gases for use as fueladditives. However, a satisfactory hydrogen generating system thatefficiently uses the power supplied to the system and generates asufficient supply of gases at acceptable temperatures does not yetexist.

BRIEF DESCRIPTION

In one aspect, a hydrogen generating system includes a plurality ofconductive plates, a first connector and a second connector. Eachconnector is connected to at least some of the plates, an amperagesensor configured to measure an actual amperage of the hydrogengenerating system, and a temperature sensor configured to measure anactual temperature of the hydrogen generating system, and a controller.The controller includes a processor programmed to receive a targetamperage, a maximum amperage threshold, a maximum temperature threshold,and an optimal temperature, select, based on the target amperage,certain of the plurality of conductive plates to receive an appliedvoltage, receive a measurement of an actual amperage and an actualtemperature from the amperage sensor and the temperature sensor,respectively, compare the actual amperage and the actual temperature tothe maximum amperage threshold and the optimum temperature,respectively, and adjust the applied voltage based on the comparison.

In another aspect, a method of controlling a hydrogen generating systemhaving a plurality of conductive plates includes receiving a targetamperage, a maximum amperage threshold, and an optimal temperature. Themethod also includes applying a voltage to at least some of theplurality of conductive plates in the hydrogen generating system,obtaining an actual amperage and an actual temperature of the hydrogengenerating system, comparing the actual amperage to the maximum amperagethreshold and the actual temperature to the optimal temperature, andadjusting at least one of the applied voltage and a duty cycle based onthe comparison.

In still another aspect, a computer readable medium has instructionsrecorded thereon that when executed by a processor cause the processorto receive a target amperage, a maximum amperage threshold, and anoptimal temperature, apply a voltage to at least some of a plurality ofconductive plates in a hydrogen generating system, obtain an actualamperage and an actual temperature of the hydrogen generating system,compare the actual amperage to the maximum amperage threshold and theactual temperature to the optimal temperature, and adjust at least oneof the applied voltage and a duty cycle based on the comparison.

Various refinements exist of the features noted in relation to theabove-mentioned aspects. Further features may also be incorporated inthe above-mentioned aspects as well. These refinements and additionalfeatures may exist individually or in any combination. For instance,various features discussed below in relation to any of the illustratedembodiments may be incorporated into any of the above-described aspects,alone or in any combination.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of a hydrogen generating system of one suitableembodiment;

FIG. 2 is a perspective of a frame of the device of FIG. 1;

FIG. 3 is an exploded view of the frame;

FIG. 4 is a front view of a reservoir of the system of FIG. 1;

FIG. 5 is an exploded cross-section taken in the plane of line 5-5 ofFIG. 4;

FIG. 6 is an exploded view of a housing of the system of FIG. 1;

FIG. 7 is a top plan view of the housing;

FIG. 8 is a cross-section taken in the plane of lines 8-8 of FIG. 7;

FIG. 9 is a bottom perspective of a lid of the housing of FIG. 1;

FIG. 10 is a bottom plan view of the lid of FIG. 9;

FIG. 11 is a front elevation of the lid;

FIG. 12 is a front elevation of the housing and showing a heater of thesystem;

FIG. 13 is an exploded view of an electrode plate assembly of thehousing of FIG. 6;

FIGS. 14A-14D are perspectives of plates of the electrode plateassembly;

FIGS. 15A-15B are perspectives of connectors of the electrode plateassembly;

FIGS. 16A-16C are perspectives of a retention bracket of the electrodeplate assembly;

FIG. 17 is a perspective of a plate assembly of a second embodiment;

FIG. 18 is a block diagram of a vehicle including a hydrogen generatingsystem;

FIG. 19 is a block diagram of a hydrogen generating system including anexample electronic controller;

FIGS. 20 and 21 are flow charts showing an operation of the electroniccontroller;

FIG. 22 is a flow chart showing an operation of the electroniccontroller dynamically adding or removing a quantity of active plates;

FIG. 23 is a schematic of another embodiment of an electrode plateassembly;

FIG. 24 is a graph showing how the electronic controller can determinewhich plate set is active;

FIG. 25 is a graph that illustrates gas production versus time;

FIG. 26 is a graph that illustrates temperature versus time;

FIG. 27 is a graph that illustrates amperage versus time;

FIG. 28 is a graph that illustrates efficiency versus time;

FIG. 29 is a graph that illustrates gas production versus temperature;

FIG. 30 is a perspective of a hydrogen generating system of anotherembodiment;

FIG. 31 is a front elevation of the system of FIG. 30 with a housingremoved to show a plate assembly;

FIG. 32 is a cross-section taken in the plane of lines 33-33 of FIG. 30;and

FIG. 33 is a cross-section taken in the plane of lines 33-33 of FIG. 30.

DETAILED DESCRIPTION

Referring now to the drawings and particularly to FIG. 1, a fuelemission device or hydrogen generating system of one suitable embodimentis generally designated 11. The hydrogen generating system 11 generallycomprises a housing 13 and a frame 15 for supporting the housing 13. Inthis embodiment, the hydrogen generating system 11, and in particularthe housing 13 and the frame 15, are adapted for mounting on a vehicle19 (see FIG. 18), such as a diesel tractor of a tractor-trailercombination, and operably connected to an internal combustion engine 21(see FIG. 18). A power source of the hydrogen generating system 11 maybe, for example a 12 volt or a 24 volt source, though the hydrogengenerating system 11 may be adapted to multiple voltage sources. Thisembodiment also includes a reservoir 25 containing maintenance solution27, as shown in FIG. 5, for facilitating continued operation of thehydrogen generating system 11. The reservoir 25 may, however, be omittedwithin the scope of this disclosure.

As shown in FIGS. 2 and 3, the frame 15 includes a floor 31 supportingthe housing 13, side walls 33, and a back wall 35 (each of which arebroadly referred to as “frame members”) such that the housing 13 issurrounded on three sides. In other embodiments, the back wall 35 may beomitted. Upper ends of the side walls 33 have outwardly extendingflanges 37. L-shaped brackets 39 are sized to engage the flanges 37 andto secure the housing 13 on the frame 15. The frame members are suitablysecured by fasteners 41 (e.g., bolts and nuts), but may be secured inother ways, and may also be made as a one-piece unitary frame.

The frame 15 also includes an upright panel 43 secured to the back wall35. The upright panel 43 has side flanges 45 along both vertical edgesthat extend forward around the side walls 33. The side flanges 45 addstrength to the upright panel 43. The frame 15 is suitably made ofsteel, though other materials may be used.

Referring to FIGS. 4-5, the reservoir 25 includes a top 51, a bottom 53,a front wall 55, a right wall 56, a left wall 57, and a back wall 58.The back wall 58 is generally flat and includes flanges 61 having holes63 therein for receiving fasteners (not shown) therethrough. Thefasteners secure the reservoir 25 to the upright panel 43 of the frame15.

The reservoir 25 includes a relatively large opening 64 formed in a neck65 at the top 51 of the reservoir 25. The opening 64 is closed by aremovable cap 67 that is suitably secured to the neck 65 (e.g.,releasably secured by threads, not shown). The reservoir 25 alsoincludes an outlet port 69 extending from the bottom 53 of the reservoir25. A suitable conduit such as a tube 71 (see FIG. 1) connects theoutlet port 69 to the housing 13.

Referring to FIGS. 6-8, the housing 13 defines an interior chamber 75containing an electrolyte solution 77, an electrode plate assembly 79, agasket 81 and a lid 83. The electrode plate assembly 79 is generallyreceived in the chamber 75, and at least partially submersed, and moresuitably fully submersed in the electrolyte solution 77. The gasket 81of this embodiment is an O-ring made of a material capable ofwithstanding high temperatures, such as 250° F. and is generally adaptedto facilitate sealing the housing 13. The lid 83 of this embodiment isalso generally rectangular and is configured to cover the chamber 75.The gasket 81 and the lid 83 are adapted to seal the housing 13.

Referring to FIGS. 9-11, the lid 83 includes a set of channels 87 formedin an inner surface 89 of the lid 83 for channeling gas generated withinthe chamber 75 to a dome portion (e.g., collector 91) of the lid 83. Inthis embodiment, the channels 87 are V-shaped in cross-section and anend of each of the channels 87 are adjacent to an end of the lid 83.Each of the channels 87 extend generally from the end adjacent to thelid 83 to the collector 91. An outlet 93 is disposed at an apex of thecollector 91. A suitable delivery system, such as conduit 95 (seeFIG. 1) connects the outlet 93 to the engine 21 of the vehicle 19 (seeFIG. 18). The lid 83 has holes 96 around the periphery 97 for receivingfasteners that secure the lid 83 to the housing 13. The lid 83 has asquare recess 99 for receiving a temperature sensor 101 (e.g., athermistor) to sense the temperature of the hydrogen generating system11. The sensor 101 may be disposed inside or outside the chamber 75, andmay be disposed anywhere on the housing 13.

The delivery system may also include a condenser 100 disposed along theconduit 95 for inhibiting water vapor from entering the engine 21. Thecondenser may suitably be a bubbler-type condenser, though other typesare contemplated.

Referring to FIGS. 6 and 12, the housing 13 has a generally rectangularopening for receiving the electrode plate assembly 79 when the lid 83 isremoved. The housing 13 also has four generally upright sides 103 and abottom 105. Ribs 106 on the sides 103 strengthen the housing 13. Thehousing 13 includes a flange 107 along an upper edge that mates with thelid 83. Fasteners 98 extend through the lid 83 and the flange 107 of thehousing 13.

The housing 13 of this embodiment is of unitary, one-piece construction.The housing 13 is made of a crack and corrosion resistant material.Also, the material may be non-insulating so that thermal energy (e.g.,heat) can be more easily transmitted through the housing 13. Onesuitable material for the housing 13 is high-density polyethylene whichcan be molded to form the housing 13. Other materials may be usedwithout departing from the scope of this disclosure.

As shown in FIG. 12, an exterior of the bottom 105 of the housing 13includes a central recess 109. The recess 109 spaces a portion of thehousing 13 above the frame 15, and is suitably configured to accommodatea heater 110 in abutting, thermal communication with the exterior of thebottom 105 (or generally the underside) of the housing 13. The heater110 may be any suitable type of heater, including for example a radiantheater. The heater 110 may be used to warm the housing 13 and thesolution 77 therein to an operating temperature more quickly.

Referring to FIG. 13, the electrode plate assembly 79 generally includeselectrode plates, suitable brackets 121 (e.g., retention brackets), andconnection posts 141. The electrode plates in this embodiment may begenerally characterized as one of a neutral plate 125N (FIG. 14A), ananode plate 125A (FIG. 14B), or a cathode plate 125C (FIG. 14C). Eachelectrode plate is generally rectangular and may include notches 129along each edge. For example, as shown in FIG. 14A, the neutral plate125N includes one notch 129 on a top edge 136, one notch 129 on eachside edge 137, and two notches 129 along a bottom edge 138 toaccommodate retention brackets 121. Each electrode plate may havefastener holes 131 in a periphery of each electrode plate for receivingfasteners 122 therethrough for use in securing the retention brackets121 on the electrode plate assembly 79.

One or more of the electrode plates may include surface features, suchas openings or holes, that are sized and shaped to increase a surfacearea and “active sites” of the one or more electrode plates. As shown inFIG. 14A, suitable surface features include a plurality of holes in theform of slots 133 formed in a central section of the neutral plate 125N.Other shapes of openings are contemplated within the scope of thedisclosure. The slots 133 provide an increase in surface area of atleast about 0.3%, and in some embodiments at least about 0.5%, whencompared to a hypothetical plate of the same dimensions but withoutsurface features. A ratio of surface area of each electrode plate havingsurface features as compared to the hypothetical electrode plate withoutsuch features is at least 1.03, and in some embodiments at least about1.05.

In one example (further described below in the Example surface areasection) each electrode plate is 0.40005×0.17780×0.00160 meters (16gauge) and includes 200 slots 133. Each slot 133 has a radius of 0.00117meters. This configuration results in an increase in surface area ofabout 0.5% (with a ratio of 1.005) when the surface area of an electrodeplate includes openings as compared to the hypothetical plate withoutsuch openings. In this embodiment, the cathode plate 125C and the anodeplate 124A do not include slots 133, but only holes 131 for receivingthe fasteners 122 therethrough. However, other embodiments have smallslots 133 in the anode plate 125A and/or the cathode plate 125C. Theelectrode plates may have other surface features for increasing surfacearea (e.g., additional surfaces, slits, holes, bumps, projections, or arough or an abraded surface). For example, the plate 125D of FIG. 14Dincludes projections 134 extending outward from a surface or face of theplate 125D, and dimples or impressions 135 extending inward into thesurface.

In one suitable plate assembly shown in FIG. 13, cathode plates 125C(first and second cathode plates) are disposed at each end of theelectrode plate assembly 79 so that the plates are in spaced apartrelationship. An anode plate 125A is separate from the cathode plates125C and disposed in a center of the electrode plate assembly 79intermediate the cathode plates in spaced apart relationship therewith.A plurality of neutral plates 125N are disposed between each cathodeplate 125C and the anode plate 125A, each neutral plate in spacedrelationship with the anode plate and the cathode plates.

The cathode plates 125C and the anode plate 125A may be swapped suchthat one anode plate 125A is at each end of the electrode plate assembly79 and one cathode plate 125C is in the center of the electrode plateassembly 79. The number of neutral plates 125N may also vary. Inembodiments, for example, there may be 18 neutral plates 125N, 16neutral plates 125N, 14 neutral plates 125N, 12 neutral plates 125N, 10neutral plates 125N, or 8 neutral plates 125N. In the latter embodiment(8 neutral plates 125N), there are a total of 11 electrode plates (8neutral plates 125N, one anode plate 125A, and two cathode plates or endplates 125C).

One advantage of using more electrode plates is that using moreelectrode plates enables the hydrogen generating system 11 to operate ata lower temperature. For example, in embodiments where the anode plate125A is in the center of the electrode plate assembly 79, the number ofneutral plates 125N on either side of the anode plate 125A may be equal.However, other numbers and configurations of the electrode plates arecontemplated.

Two cathode plates 125C may be electrically connected by suitableconnectors, such as by a U-shaped connector 139 shown in FIG. 15A or byother suitable connector(s). A post 141 extends upward from the U-shapedconnector 139. In this embodiment, the post 141 is suitably a “clench”or threaded fastener that is joined to the U-shaped connector 139 by anut 143. The post 141 may be joined to the U-shaped connector 139 by aseparate fastener, by welding, or the like. The post 141 may also beformed as one-piece with the U-shaped connector 139. Likewise, theU-shaped connector 139 is suitably joined to the cathode plates 125C bya fastener, but may be joined in other suitable ways. For example, theU-shaped connector 139 and the post 141 may also both be formed asone-piece with one or both of the cathode plates 125C.

An L-shaped connector 147 (FIG. 15B) has the post 141 extending upwardfrom a main surface of the L-shaped connector 147. The L-shapedconnector 147 is suitably joined to the anode plate 125A at a top edgeof the anode plate 125A by threads as described above. Like the U-shapedconnector 139 of FIG. 15A, the post 141 may be made as one-piece withthe L-shaped connector 147 and the anode plate 125A. The posts 141 aresuitably connected to the power source by wires (not shown).

In the embodiment shown in FIG. 13, the electrode plate assembly 79 mayalternatively be referred to as a “cell.” In further embodiments, morethan one electrode plate assembly 79, or cell, may be used. For example,a second electrode plate assembly, or cell, may be added to theelectrode plate assembly 79, described above, and more suitably anon-conductive barrier may be disposed between each of the electrodeplate assemblies.

Each electrode plate is made of a suitable material that is resistant toreactivity with the solution 77 or amperage applied. In one embodiment,the electrode plates are made of a 316L stainless steel. The material ofan electrode plate is chosen to have an appropriate resistance. Eachelectrode plate should be sufficiently thick to reduce electricalresistance and to inhibit significant flexing of the electrode plates.In some embodiments, each electrode plate is between 16 gauge and 20gauge, and in one embodiment each electrode plate is 20 gauge. Note thata resistance of a wire (and by analogy an electrode plate) is generallyaffected by four factors: (1) material (for example, gold and silverhave relatively low resistance), (2) a thickness of the wire or theelectrode plate, (3) a temperature of the wire or the electrode plate,and (4) a length of the wire (but a length of an electrode plate is notan applicable factor). The thicker an electrode plate, the more spaceexists for a current to flow. As an electrode plate warms up, there ismore energy therein and a resistance to a current and an electron flowdecreases.

Referring to FIGS. 16A-C, each retention bracket 121 is generallyU-shaped. Each bracket 121 is generally “combed”, meaning that eachbracket 121 includes a bridge 148 and a plurality of spacers 149 (orteeth) spaced apart such that one electrode plate fits between twoadjacent spacers 149. Spacing between spacers 149 is uniform so that aspacing between each electrode plate is equal. In one embodiment, forexample, the spacing between each electrode plate is suitably betweenabout 2.0 mm and about 6.5 mm. Fasteners (for example, the fasteners122) extend through the brackets 121 and through the electrode plates tosecure the stack (e.g., the electrode plate assembly), together. Eachbracket is suitably made of an electrically non-conductive material.

Referring to FIG. 17, in this embodiment, there are 12 interleavedelectrode plates 151. The electrode plates 151 may be formed asdescribed above (e.g., of low carbon stainless steel). Each electrodeplate 151 is configured for an electrical connection point 153 at oneend of each electrode plate 151, for a total of 12 connection points.The plates are interleaved such that connection points of adjacentplates 151 are opposite one another. A first set of electricalconnections 153 are attached (e.g., by jumper wires) to connector blocks156, with a corresponding second set of electrical connections 153 beingattached to a respective wire harnesses (not shown) and connected to anelectrical controller 202 (see FIG. 19). Generally, the controller 202switches an electrical current to various combinations of electrodeplate sets to develop a best use of current in the hydrogen generatingsystem 11, such as by the method described below.

Generating system 11′ of another embodiment shown in FIG. 23 and FIGS.30-32 is similar to the system 11 of FIGS. 1-12. The positioning of theelectrode plates in generating system 11′ is shown schematically in FIG.23 and described in more detail in the Example System below. In thisembodiment, plate assembly 502 includes 22 electrode plates (six anodeplates 510, 512, 514, 516, 518, 520, one cathode plate 508, and 15neutral plates 524). Alternatively, the anode plates may instead becathode plates, and the cathode plate may be an anode plate. Also, ifnot energized, the anode plates 510, 512, 514, 516, 518, 520 serve asneutral plates. As shown, the cathode plate 508 includes a post 509 thatextends through the lid 83, and each anode plate 125A includes a similarpost 511 that extends through the lid 83 at an opposite end of the lid83.

The brackets 121′ of this embodiment include spacers 122′ that extendupward about 1.5 inches. The brackets 121 are sized such that there isabout 0.25 inches clearance between a bottom of the electrode plates andthe housing 13. The brackets 121 may also be beveled to provideclearance of the electrode plates relative to the housing 13.

Referring to FIG. 32, a float mechanism 124 extends from a port in thelid 83. The float mechanism 124 serves to ensure that the solution 77′is at a level above a top of the electrode plate assembly 502. The floatmechanism 124 is suitably a conventional float 126 similar to a typeused in a home toilet tank. The mechanism 124 is in fluid communicationwith the solution 77′ in the chamber 75′ and with the reservoir 25 viatube 71′. When the level of the solution 77′ begins to fall, the float126 pivots downward, opening a valve that allows maintenance solution(e.g., solution 27) from the reservoir 25 to enter the chamber 75′. Asthe level of the solution 77′ rises, the float 126 moves upward andcloses the valve. Note that the reservoir 25 is suitably disposed abovethe housing 13′ for gravity flow of the maintenance solution to thechamber.

One advantage of some embodiments of this disclosure is that eachelectrode plate can be monitored to control an amperage level generated.As described in detail below, power can be channeled to each electrodeplate as needed to increase hydrogen production for a given amperage.This can increase the generation of hydrogen and oxygen available atstart-up and significantly reduce a usual warm-up period required to getthe hydrogen generating system 11 to full production at optimumtemperature.

Starter and Maintenance Solutions:

The housing 13 or 13′ has sufficient fluid (e.g., electrolyte solution77) therein so that the electrode plates are submersed in the fluid.Opposite faces (both faces) of the electrode plates (any of the platesdescribed herein) are exposed to the electrolyte solution. Also, thesurface features as described herein are exposed to the solution. Thefluid of one embodiment is a solution having 20-320 mL of 2.14 molarpotassium hydroxide diluted to 11.353 liters. In this embodiment, theelectrolyte suitably contains color and buffers.

In the above embodiment, 200 mL of 2.14 molar solution is added to thechamber 75 or 75′ and diluted with distilled water to a capacity of thechamber, for example 11.353 liters. A concentration of electrolytefacilitates the electrical current through the aqueous solution.

The reservoir 25 holds a maintenance solution (e.g., solution 27). Inone embodiment, the maintenance solution includes two buffer solutionsand distilled water, though it is contemplated to use only distilledwater. The first buffer is alkaline, and includes boric acid (H₂B₄O₇)and Sodium hydroxide, N_(a)OH. The solution has a pH of about 12.7. Inone embodiment, there is between 25 grams and 35 grams of boric acid andbetween about 9 grams and 15 grams of sodium hydroxide, in anotherembodiment between about 30 and 32 grams of boric acid and between 11grams and 13 grams of sodium hydroxide, and in one embodiment about 31.4grams of boric acid and about 12 grams of sodium hydroxide. In oneembodiment, the solution is made by dissolving the boric acid and sodiumhydroxide in 1 liter of distilled water. This yields 0.1 Mconcentrations of each species. Then 10 mL of the solution is added to3.7843 liters of distilled water. A suitable dye, such as bromothymolblue, may then be added.

The second buffer solution for the maintenance solution is also alkalineand includes dipotassium phosphate (K₂HPO₄) and tripotassium phosphateK₃PO₄. The solution has a pH in a range of 10-14, or in some embodimentsbetween 11 and 13, and in some embodiments about 12.7. In oneembodiment, there is between 10 grams and 20 grams of dipotassiumphosphate and between about 9 grams and 15 grams of tripotassiumphosphate, in another embodiment between about 30 grams and 32 grams ofdipotassium phosphate and between 11 grams and 13 grams of tripotassiumphosphate, and in one embodiment about 15.8 grams of dipotassiumphosphate and about 19.6 grams of tripotassium phosphate. In oneembodiment, the solution is made by dissolving the dipotassium phosphateand tripotassium phosphate in 1 liter of distilled water. This yields0.1 M concentrations of each species. Then 10 mL of the solution isadded to 3.7843 liters of distilled water. A suitable dye, such asbromothymol blue, may then be added.

Example System:

Referring to FIG. 18, an exemplary block diagram of the vehicle 19(e.g., a truck) including the hydrogen generating system 11 incommunication with the engine 21 of the vehicle is shown. Note thatsystem 11′ can be used instead. Embodiments of the disclosure enable thehydrogen generating system 11 to generate a sufficient amount hydrogengas per minute (e.g., 6 liters of hydrogen gas per minute) at a very lowtemperature (e.g., 40° F.) immediately upon start-up. Further,embodiments of the present disclosure enable the hydrogen generatingsystem to manage heat at high temperatures (e.g., 140-180° F.) whileproducing acceptable quantities of hydrogen gas (e.g., over 2 liters perminute).

Referring to FIG. 19, an exemplary block diagram of the hydrogengenerating system 11 including an electronic controller 202 is shown.Embodiments of the disclosure enable the electronic controller 202 tomonitor an actual amperage and an actual temperature of the hydrogengenerating system 11. Further, the embodiments described herein enablethe hydrogen generating system 11 to achieve increased amperage betweenelectrode plates of a cell substantially immediately upon a start-up ofthe hydrogen generating system 11 by effectively omitting a quantity ofelectrode plates over which a voltage is applied.

The electronic controller 202 as described herein has one or moreprocessors 204 or processing units, a memory area 206, and some form ofcomputer readable media. By way of example and not limitation, computerreadable media comprise computer storage media and communication media.Computer storage media include volatile and nonvolatile, removable andnon-removable media implemented in any method or technology for storageof information such as computer readable instructions, data structures,program modules or other data. Communication media typically embodycomputer readable instructions, data structures, program modules, orother data in a modulated data signal such as a carrier wave or othertransport mechanism and include any information delivery media.Combinations of any of the above are also included within the scope ofcomputer readable media.

Although the processor(s) 204 is shown separate from the memory area206, embodiments of the disclosure contemplate that the memory area 206may be onboard the processor(s) 204 such as in some embedded systems.The processor(s) 204 executes computer-executable instructions forimplementing aspects of the disclosure. For example, the processor(s)204 is programmed with instructions such as illustrated in FIGS. 20-22.The computer-executable instructions may be organized into one or morecomputer-executable components or modules. Generally, program modulesinclude, but are not limited to, routines, programs, objects,components, and data structures that perform particular tasks orimplement particular abstract data types. Aspects of the presentdisclosure may be implemented with any number and organization of suchcomponents or modules. For example, aspects of the invention are notlimited to the specific computer-executable instructions illustrated inthe figures and described herein. Other embodiments of the invention mayinclude different computer-executable instructions. Aspects of thedisclosure may also be practiced in distributed computing environmentswhere tasks are performed by remote processing devices that are linkedthrough a communications network. The processor(s) 204 is transformedinto a special purpose microprocessor by executing computer-executableinstructions or by otherwise being programmed.

The electronic controller 202 may be in communication with a displaydevice (not shown) separate from or physically coupled to the hydrogengenerating system 11. The display device may be a capacitive touchscreen display, or a non-capacitive display. User input functionalitymay also be provided in the display, where the display acts as a userinput selection device such as in a touch screen. The display device mayprovide a user with information regarding the hydrogen generating system11, such as, temperature, measured amperage, error messages, and thelike.

In this embodiment, the hydrogen generating system 11 includes atemperature sensor (e.g., temperature sensor 101) configured to measurean actual temperature of the hydrogen generating system 11. Thetemperature sensor 101 may be disposed on the outside of the housing 13.Due to the thermal properties of the housing 13, a temperature dropacross a wall of the housing 13 is minimal so that the sensed/measuredtemperature is relatively close to the temperature inside the housing13. However, the temperature sensor 101 may alternatively be disposedinside the housing 13.

A time from a start-up to optimum operating temperature (e.g., about140° F. to about 160° F.) of the hydrogen generating system 11 is afunction of an amount of amperage generated by electrolysis. Therefore,as temperature increases, amperage increases, and an efficiency forproducing hydrogen gas increases. An amperage sensor (not shown) may beused to measure an actual amperage of the hydrogen generating system 11.In a further embodiment, the hydrogen generating system 11 includesresistors configured to measure an actual amperage.

Referring next to FIG. 20, a flow chart showing an operation of theelectronic controller 202 is shown. Upon a start-up of the hydrogengenerating system 11, at 208 a target amperage (e.g., about 20 amps toabout 30 amps) and a maximum threshold temperature (e.g., about 180° F.)is received. The target amperage and the maximum threshold temperaturemay be automatically set by a manufacturer and/or manually selected by auser via the display device.

To control amperage, the electronic controller 202 enables eachelectrode plate in the electrode plate assembly 79 to be individuallymonitored and controlled. At 210, a quantity of electrode plates lessthan a total quantity of the electrode plates in the electrode plateassembly 79 to apply a voltage to is selected. Choosing to apply avoltage across a selected quantity of electrode plates less than a totalquantity of the electrode plates in the electrode plate assembly 79 canresult in higher currents dissipating more power. This causes a fasterrise in a temperature of an electrolyte between the electrode plates towhich the voltage is applied (e.g., the active electrode plate set),thereby increasing production of hydrogen gas that is being produced bythe active electrode plates. For example, as temperature increases, theelectrolyte becomes more conductive, enabling an inclusion of additionalelectrode plates in the active electrode plate set and thus increasingthe efficiency of hydrogen gas produced by the hydrogen generatingsystem 11. Applying a voltage across a quantity of electrode plates lessthan a total quantity of electrode plates in the electrode plateassembly enables the hydrogen generating system to generate at least 2liters of hydrogen gas per minute at a very low temperature (e.g., 40°F.) substantially immediately upon start-up. In one embodiment, only theelectrode plates required to achieve the target amperage receive anapplied voltage. The quantity of the plurality of electrode plates thatreceive the applied voltage may be based on at least one of thefollowing: a temperature of an electrolytic solution, an amount ofvoltage applied, a distance between each of the plurality of electrodeplates (e.g., about 3 mm), and a type and concentration of electrolyticsolution used. This can increase generation of hydrogen and oxygenavailable at start-up and significantly reduce a warm-up period requiredto get the hydrogen generating system 11 to full production at optimumtemperature, the process of which is described in detail below.

The electronic controller 202 provides a pulse of electricity at aparticular voltage for a duty cycle of, for example, 4 ms (fourmilliseconds). The length of the duty cycle (i.e., 4 ms) is merelyexemplary and is not intended to limit the scope of the presentdisclosure. One of ordinary skill in the art will appreciate thatvarious lengths of time may be used, for example, 8 ms, 12 ms, and 14 msmay be used. A duty cycle may be limited by applying the pulse for afraction of the duty cycle. For example, with a duty cycle of 4 ms, apulse may be applied for only 3 ms of the 4 ms duty cycle, 2 ms of the 4ms duty cycle, or even 1 ms of the 4 ms duty cycle. In furtherembodiments, the pulse applied during the 4 ms duty cycle can be dividedeven further, for example, to 1/16 or 1/32 of the 4 ms duty cycle.

After a voltage is applied to the selected quantity of plates, at 212,an actual amperage and an actual temperature of the hydrogen generatingsystem 11 are measured. To compensate for an increased temperature asthe process of electrolysis occurs, the electronic controller 202 caneffectively lower the voltage applied to the selected number of theplurality of plates (e.g., by decreasing the time a pulse is applied inthe duty cycle) to maintain the amperage at a desired level duringoperation. For example, at 214, the electronic controller 202 isconfigured to compare the actual amperage to an amperage threshold(e.g., 25 amps), compare the actual temperature to a maximum thresholdtemperature (e.g., 160° F.), and at 216, adjust at least one of a dutycycle and/or the applied voltage based on the comparisons in order toregulate the actual temperature and the actual amperage. For example, ifit is determined that an actual amperage exceeds a maximum amperagethreshold (e.g., 30 amps) and/or the actual temperature is greater thanthe optimal temperature, the duty cycle may be adjusted to enable anaverage of an actual amperage to substantially equal the targetamperage. In contrast, if it is determined that the actual amperage isequal to or less than the maximum amperage threshold, and the actualtemperature is less than or equal to the optimal temperature, at 218,the duty cycle may be increased. For example, a maximum voltage may beapplied to the selected quantity of plates for at least one duty cycle.Next, the actual amperage and the actual temperature of the hydrogengenerating system are measured again, and the process is repeated.

Referring next to FIG. 21, an additional flow chart showing an operationof the electronic controller 202 is shown. At 302, upon aninitialization of the processor(s) 204 and other hardware associatedwith the hydrogen generating system 11, a target amperage (e.g., about20 amps and about 30 amps), an optimal temperature (e.g., about 160°F.), and a maximum threshold temperature (e.g., 180° F.) aredetermined/received at 304. In one embodiment, the optimal temperatureis a range of temperatures, for example, the optimal temperature may bea temperature between 140° F. and 160° F. After the target amperage, theoptimal temperature, and the maximum threshold temperature aredetermined/received, a voltage is applied to at least some (e.g., aselected quantity) of the plurality of plates in the hydrogen generatingsystem.

Using the amperage sensor (not shown) and the temperature sensor 101, at306, an actual amperage and an actual temperature of the hydrogengenerating system 11 are determined/obtained, and thereafter, comparedto the target amperage and the optimal temperature, respectively. At308, if the actual amperage is below the maximum amperage threshold(e.g., an amperage that does not overburden a battery of the vehicle19), and if the actual temperature is below the optimal temperature, at310, full voltage is applied for at least one duty cycle.

At 312, if the actual amperage exceeds the maximum amperage threshold,i.e., the current reaches a level where components may be damaged, andif the actual temperature is below the optimal temperature, at 314, aduty cycle is computed resulting in an increased temperature. As oneexample, the maximum amperage threshold may be 50 amps. However, at 316,if the actual temperature equals the optimal temperature, at 318, a dutycycle is computed and a rated amount of hydrogen gas is produced.

If however, at 316, the actual temperature exceeds the optimaltemperature, at 320, a duty cycle is reduced to maintain thetemperature. After the duty cycle is reduced, the actual amperage iscompared to the maximum safe amperage. If, at 322, the actual amperageis less than or equal to a maximum safe amperage threshold, the actualtemperature is compared to the maximum threshold temperature. At 328, ifthe actual temperature exceeds the maximum temperature threshold, at330, a current of the hydrogen generating system 11 is turned off, anactual temperature (e.g., a second actual temperature) is measured, andthe current of the hydrogen generating system 11 is turned on when it isdetermined that the second actual temperature is below the maximumtemperature threshold.

If however, at 322, after the duty cycle has been reduced and the actualamperage exceeds a maximum safe amperage threshold (to prevent damage tothe system), at 324, the current of the hydrogen generating system 11 isturned off for a predefined period of time (e.g., three minutes). At326, after the predefined period of time, the current is turned back on.Thereafter, an actual amperage (e.g., a second actual amperage) isdetermined and compared to the maximum safe amperage, and the process isrepeated.

In addition to the above advantages, using interchangeable electrodeplates as anodes and cathodes also maximizes gas production byoptimizing the quantity of energized (e.g., active) electrode platesbased on a target amperage. As more electrode plates are energized, thequantity of electrolyte to electrode plate transitions is increasedwhich increases the gas production per amp.

A transition occurs where electricity passes from the liquid electrolyteto the metal of an electrode plate (the electrolyte/plate interface).Hydrogen gas is formed at this electrolyte/plate interface. Hence, if anelectric current makes the same amount of hydrogen gas for eachtransition from liquid to metal, the more times a current is forced tomake the transition, the more hydrogen gas is produced per amp and themore efficient the hydrogen generating system becomes.

For example, when anodes 514 and 516 in the embodiment shown in FIG. 23are energized, the electrolyte increases in temperature, becomes moreconductive, and the current increases. When the current reaches 30 amps,anodes 512 and 516 are energized. The current now drops because theadditional transitions limit the current. This process continues asanodes 512 and 518, then anodes 510 and 518, and then anodes 510 and 520are sequentially energized. After anodes 510 and 520 have beenenergized, individual anodes are energized, starting with anode 514followed in turn by anode 516, anode 512, anode 518, anode 510, andfinally anode 520. In practice, it is not necessary to perform all thesteps just described. Some steps may not be reached while others may beskipped. As further described below, any single anode, as opposed tomultiple anodes, may be selected to be energized based, for example, onamperage and/or temperature. The electrolyte concentration is set toallow sufficient current to flow at the largest plate set contemplatedto produce the desired gas. As explained above, when an amperagethreshold is detected, additional plates may be energized to enable thehydrogen generating system 11 operate at optimal production. Theconversion to an optimal operating electrode plate configuration is afactor in the increased efficiency of the electrolysis process.

Further, as a temperature of an aqueous solution increases, an amperageof the hydrogen generating system 11 also increases. Therefore, with 200mL of electrolytic solution using multiple anodes and cathodes, anactual amperage may become excessive. The methods of controlling and/orlimiting the actual amperage while allowing a use of multiple anodes andcathodes described above enable a use of the multiple anodes andcathodes to provide constant amperage from a start-up of theelectrolytic generating system 11 until it is turned off.

Although described in connection with an exemplary computing systemenvironment, embodiments of the disclosure are operational with numerousother general purpose or special purpose computing system environmentsor configurations. Examples of well known computing systems,environments, and/or configurations that may be suitable for use withaspects of the disclosure include, but are not limited to, mobilecomputing devices, personal computers, server computers, hand-held orlaptop devices, multiprocessor systems, microprocessor-based systems,programmable consumer electronics, mobile telephones, network PCs,minicomputers, mainframe computers, distributed computing environmentsthat include any of the above systems or devices, and the like.

A method for dynamically adding or removing a quantity of activeelectrode plates based on actual amperage will now be described withreference to FIGS. 22-28.

FIG. 22 is a flow chart showing an operation of the electroniccontroller 202 dynamically adding or removing a quantity of activeelectrode plates from an electrode plate assembly (e.g., electrode plateassembly 502 in FIG. 23) based on at least one of an actual amperage andan actual temperature.

At 402, upon receiving a minimum amperage threshold, a maximum amperagethreshold, a maximum temperature threshold, and an actual temperature(e.g., first actual temperature of the hydrogen generating system 11),at 404, the electronic controller 202 selects a first plurality ofplates (e.g., an initial plurality of plates) from the electrode plateassembly 502. The selection of the first plurality of plates is based onat least one of the following: the minimum amperage threshold, themaximum amperage threshold, and the first actual temperature of ahydrogen generating system. The first actual temperature may be thetemperature of the hydrogen generating system 11 upon start-up. Afterthe first plurality of plates is selected, at 406, a voltage is appliedto the first plurality of plates.

After the voltage is applied to the first plurality of plates, at 408,an actual amperage (e.g., a first actual amperage) and an actualtemperature (e.g., a second actual temperature) of the hydrogengenerating system 11 is determined. At 410, the first actual amperage iscompared to the minimum amperage threshold and the maximum amperagethreshold. At 412, if it is determined, based on the comparison, thatthe first actual amperage is between the minimum amperage threshold andthe maximum amperage threshold, at 414, a voltage is again applied tothe first plurality of electrode plates. If however, at 412, it isdetermined that the first actual amperage is not between the minimumamperage threshold and the maximum amperage threshold, and, at 416, thefirst actual amperage is greater than or equal to the maximum amperagethreshold, at 418, a second plurality of electrode plates is selectedfrom the electrode plate assembly 502 whereafter a voltage is applied tothe second plurality of electrode plates.

If however, at 412, it is determined that the first actual amperage isnot between the minimum amperage threshold and the maximum amperagethreshold, and, at 416, the first actual amperage is not greater than orequal to the maximum amperage threshold, at 420, it is determined if thefirst actual amperage is less than or equal to the minimum amperagethreshold. If, at 420, the first actual amperage is less than or equalto the minimum amperage threshold, the second plurality of platesselected includes more plates than the first plurality of plates.However, if the second actual amperage is equal to the minimum amperagethreshold or if the second actual amperage is below the minimum amperagethreshold, at 422, a second plurality of electrode plates that includesfewer plates than the first plurality of plates is selected from theelectrode plate assembly 502.

FIG. 23 is a further example of an electrode plate assembly (e.g., theelectrode plate assembly 502 described above). The electrode plateassembly 502 can be used in place of the assembly shown above in FIGS.6-8 in a housing, such as housing 13′, sized accordingly.

The electrode plate assembly 502 includes two cells (e.g., cell 504 andcell 506) that share a common cathode 506. The present disclosureenables the cells 504 and 506 to operate (or run) in parallel to achievea sufficient amount of hydrogen gas production (e.g., about 2 liters ofhydrogen gas per minute) at low temperatures (e.g., about 40° F.). Thecell 504 includes 11 electrode plates, three of which are anodes (e.g.,anode 510, anode 512, and anode 514) and one of which is the cathode508. The cell 506 includes 12 electrode plates, three of which areanodes (e.g., anode 516, anode 518, and anode 520) and one of which isthe cathode 508. By providing two cells that are asymmetrical (cell 504including 11 electrode plates, and the cell 506 including 12 electrodeplates), increased control and increased resolution is obtained. Thatis, with the cells operating in parallel, the electronic controller 202is able to increase and decrease a quantity of active electrode platesin smaller amounts, described below.

In this embodiment, a distance between each electrode plate in theelectrode plate assembly 502 is suitably about 3 mm, and a thickness ofeach electrode plate is suitably about 20 gauge. One of ordinary skillin the art will appreciate that a quantity of electrode plates, adistance between each electrode plate, and a thickness of each electrodeplate are merely exemplary and are not intended to limit the scope ofthe present disclosure.

The electrode plate assembly 502 is configured to have a voltage appliedto a quantity of electrode plates less than the total quantity ofelectrode plates in each cell 504 and 506. To achieve this, the totalquantity of electrode plates (e.g., 22 plates with the cells 504 and 506operating in parallel) are separated into electrode plate sets (e.g.,electrode plate set 1, electrode plate set 2, electrode plate set 3,electrode plate set 4, and electrode plate set 5). Each electrode plateset has a different quantity of electrode plates. In this embodiment, aquantity of electrode plates in each electrode plate set increases fromelectrode plate set 1 to electrode plate set 5. For example, electrodeplate set 1 includes 14 electrode plates, electrode plate set 2 includeselectrode 16 plates, electrode plate set 3 includes 18 electrode plates,electrode plate set 4 includes 20 electrode plates, and electrode plateset 5 includes 22 electrode plates. Each of the electrode plate sets aredefined by anode plates at opposing ends of each electrode plate set.For example, electrode plate set 1 has anode 514 and anode 516 atopposing ends, electrode plate set 2 has anode 512 and anode 516 atopposing ends, electrode plate set 3 has anode 512 and anode 518 atopposing ends, electrode plate set 4 has anode 510 and anode 518 atopposing ends, and electrode plate set 5 has anode 510 and anode 520 atopposing ends.

FIG. 24 is a graph that includes data that further illustrates how theelectronic controller 202 determines which electrode plate set is active(e.g., which electrode plate set receives a voltage). In thisembodiment, the determination is based on a target amperage, and morespecifically, a target amperage range bound by a minimum amperagethreshold and maximum amperage threshold. In this example, the minimumamperage threshold is 20 amps and the maximum amperage threshold is 30amps. The minimum amperage threshold and the maximum amperage thresholdmay be automatically set and/or manually selected by a user via thedisplay device. Furthermore, the minimum amperage threshold of 20 ampsand the maximum amperage threshold of 30 amps are merely exemplary arenot intended to limit the scope of the present disclosure.

Generally speaking, at any given temperature, amperage decreases as aquantity of active electrode plates increase. In addition, at any givenquantity of active electrode plates, amperage increases as temperatureincreases. Based on this understanding, at a given temperature, applyinga voltage to an electrode plate set with a lesser quantity of electrodeplates will return a higher amperage compared to applying a voltage toan electrode plate set with a greater quantity of electrode plates atthe same temperature. Therefore, when a voltage is applied to aparticular electrode plate set and an actual amperage reaches themaximum amperage threshold, the electronic controller 202 activates anelectrode plate set that has a greater quantity of electrode plates thanthe presently active electrode plate set, thereby decreasing theamperage. In contrast, when a voltage is applied to a particularelectrode plate set, and an actual amperage reaches the minimum amperagethreshold, the electronic controller 202 activates an electrode plateset that has a lesser quantity of electrode plates than the presentlyactive electrode plate set, thereby increasing the amperage.

Thus, at a given temperature, applying a voltage to an electrode plateset that includes the least quantity of electrode plates (e.g., plateset 1 if the cells 504 and 506 are operating in parallel) returns thehighest amperage. Therefore, in the example shown in FIG. 24, becausethe temperature of the hydrogen generating system 11 is only at 60° F.,the electronic controller 202 initially activates electrode plate set 1,which returns an actual amperage of 34.8 amps. However, 34.8 amps isabove the maximum amperage threshold of 30 amps. Therefore, theelectronic controller 202 increases a quantity of active electrodeplates by activating electrode plate set 2. Activating electrode plateset 2 returns an actual amperage of 30.5 amps. However, 30.5 amps isstill above the maximum amperage threshold of 30 amps. Therefore, theelectronic controller 202 increases a quantity of active electrodeplates by activating electrode plate set 3. Activating electrode plateset 3 returns an actual amperage of 28 amps.

As shown in FIG. 24, the temperature of the hydrogen generating systemincreases with time. As mentioned above, as the temperature of thehydrogen generating system 11 increases, amperage increases. Therefore,while the electrode plate set 3 initially returns an actual amperage of28 amps, as time elapses, the temperature of the hydrogen generatingsystem 11 increases from 69° F. to 78° F. However, once the temperatureof the hydrogen generating system 11 reaches 78° F., the electrode plateset 3 returns an actual amperage of 30.30 amps, which is above themaximum amperage threshold of 30 amps. Therefore, the electroniccontroller 202 increases a quantity of active electrode plates byactivating electrode plate set 4, and at 78° F., the electrode plate set4 returns an actual amperage of 23.7 amps. Once the temperature of thehydrogen generating system 11 reaches 118° F., the electrode plate set 4returns an actual amperage of 31.50 amps, which is above the maximumamperage threshold of 30 amps. Therefore, the electronic controller 202increases a quantity of active electrode plates by activating electrodeplate set 5, and at 118° F., the electrode plate set 5 returns an actualamperage of 26.2 amps.

As mentioned above, using two cells (e.g., cells 504 and 506) that areasymmetrical increases control and resolution. For example, once thehydrogen generating system 11 reaches an optimal temperature, theelectronic controller 202 may stop operating each of the cells 504 and506 in parallel. In this embodiment, operating only one cell, threeelectrode plate sets are left available:

-   -   (1) electrode plate set 6, which is in the cell 506, and        includes all of the electrode plates from anode 518 to the        cathode 508, totaling 10 electrode plates;    -   (2) electrode plate set 7, which is in the cell 504, and        includes all of the electrode plates from anode 510 to the        cathode 508, totaling 11 electrode plates; and    -   (3) electrode plate set 8, which is in the cell 506 and includes        all of the electrode plates from anode 520 to the cathode 508,        totaling 12 electrode plates.

Thus, because the cell 506 has one more electrode plate than the cell504 (making the two cells asymmetrical), electrode plate sets 6, 7, and8 increase in total electrode plates by only 1 electrode plate,increasing the control and resolution.

In addition to adding and removing a quantity of active electrode platesto maintain an amperage between a minimum amperage threshold and maximumamperage threshold, if a temperature of the hydrogen generating system11 exceeds a maximum temperature threshold, the electronic controller202 may also adjust the duty cycle.

FIG. 25 is a graph that illustrates gas production versus time. Thegraph represents the results achieved by implementing what is shown inFIG. 22, where the electronic controller 202 dynamically added/removed aquantity of electrode plates and/or at least one of the applied voltageand a duty cycle based on amperage and temperature. As shown in thegraph, about 2.8 liters of hydrogen gas are produced per minute uponinitial start-up. The last two points on the graph (points 602 and 604)represent where a current was limited in order to prevent an increase intemperature.

FIG. 26 is a graph that illustrates temperature versus time. Asexpected, the temperature rises faster in the beginning when fewerelectrode plates are active, and as more electrode plates are added, therate of increase in the temperature is reduced.

FIG. 27 is a graph that illustrates current/amperage versus time. Asshown in the graph, the actual amperage decreases with time because, astime elapses, temperature increases and a quantity of active electrodeplates operated is increased to decrease the amperage (see FIG. 22).Further, power dissipated is equal to a voltage applied across a cellmultiplied by the amps passing through the cell. As amperage drops athigher temperatures, the power flowing to the hydrogen generating system11 drops and a rate of temperature rise slows down.

FIG. 28 is a graph that illustrates efficiency versus time, whereefficiency is an amount of hydrogen gas produced per amperage ofelectricity. As shown in the graph, efficiency generally improves astemperature increases and the quantity of active electrode platesincreases.

With reference back to FIG. 27, as shown in the graph, the actualamperage decreases with time. The efficiency achieved in each plate setis as follows: electrode plate set 1 (0.083), electrode plate set 2(0.092), electrode plate set 3 (0.094), electrode plate set 4 (0.104),and electrode plate set 5 (0.110). As shown here, increasing a quantityof active electrode plates between an anode and a cathode increasesefficiency.

FIG. 29 is a graph that illustrates gas production versus temperature.As shown in the graph, about 2.7 liters of gas per minute is achievableat 60° F. These numbers are merely exemplary and are not intended tolimit the scope of the present disclosure. For example, further testshave shown that 2 liters of hydrogen gas per minute can be achieved atonly 40° F., without going over 30 amps.

Opereting Environment:

In one embodiment shown in FIG. 18, the hydrogen generating system 11 ismounted in the vehicle 19, such as a truck, and is mounted outside theengine 21, for example, behind a cab of the truck. Other mountingarrangements are contemplated.

In this embodiment, the hydrogen output from the hydrogen generatingsystem 11 is directed to the engine 21 of the truck. The hydrogen gas isa supplement to the conventional fuel of such an engine (e.g., apetroleum-based fuel or “fossil fuel” such as unleaded gasoline, diesel,natural gas or propane). The hydrogen gas can improve fuel efficiency ofthe engine 21. The hydrogen gas may enable the engine 21 to meetstringent emission standards while also increasing fuel economy and/orpower output.

Example Surface Area Increase Due to Holes in the Plate: PlateParameters

-   Hole radius=0.00117 meters-   Length of plate=0.40005 meters-   Width of plate=0.17780 meters-   Thickness of plate=16 gauge=0.00160 meters-   Number of holes=200    Surface Area of Plate with no Holes

Top & Bottom

0.40005 meters×0.17780 meters=2.80035 meters² (L×W)

2.80035×2=5.6007 meters² (top and bottom) Sides

0.00160 meters×0.17780 meters×2=0.02235 meters² (short sides)

0.00160 meters×0.40005 meters×2=0.05029 meters² (long sides)

Total Surface Area of Plate

5.6007 meters²+0.02235 meters²+0.05029 meters²=5.67258 meters²

Surface Area Removed from Holes being Added

200×pi×r ²×2=200×0.07976×0.00117×0.00117×2=0.06756 in²

Surface Area Gained from Cylinders being formed at Each Hole Made

200{(2×pi×r×r)+(2×pi×r×h)−(2×pi×r×r)} Note accounts for the top/bottomcircles removed.

200{(2×0.07976 meters×0.00117 meters×0.00117 meters)+(2×0.07976meters×0.00117 meters×0.00160 meters)×(2×0.07976 meters×0.00117meters×0.00117 meters)}=200×(2×0.07976 meters×0.00117 meters×0.00160meters)=0.09446 meters²

Surface Area of Plates with Holes

Surface Area of Plates with Holes={Surface area of Solid Plate−Surfacearea of plate removed to form holes+Surface Area Gained from Formationof Cylinders where holes are made}

Surface Area of Plates with Holes=(5.67258 meters²−0.06756meters²+0.09627 meters²)=5.69620 meters²

Ratio of Surface Area of Plates with Holes vs. Solid Plate −16 Gauge

Plate with Holes/Solid Plate=5.69620/5.67258=0.02553 or 0.51% moresurface area

When introducing elements of the present invention or the embodiment(s)thereof, the articles “a”, “an”, “the” and “said” are intended to meanthat there are one or more of the elements. The terms “comprising”,“including” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

As various changes could be made in the above constructions withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description and shown in the accompanyingdrawing[s] shall be interpreted as illustrative and not in a limitingsense.

1. A hydrogen generating system comprising: a plurality of conductiveplates; a first connector and a second connector, wherein each connectoris connected to at least some of the plates; an amperage sensorconfigured to measure an actual amperage of the hydrogen generatingsystem; and a temperature sensor configured to measure an actualtemperature of the hydrogen generating system; and a controllercomprising a processor programmed to: receive a target amperage, amaximum amperage threshold, a maximum temperature threshold, and anoptimal temperature; select, based on the target amperage, certain ofthe plurality of conductive plates to receive an applied voltage;receive a measurement of an actual amperage and an actual temperaturefrom the amperage sensor and the temperature sensor, respectively;compare the actual amperage and the actual temperature to the maximumamperage threshold and the optimum temperature, respectively; and adjustthe applied voltage based on the comparison.
 2. The hydrogen generatingsystem of claim 1 wherein adjusting the applied voltage based on thecomparison comprises lowering the applied voltage if the actual amperageexceeds the maximum amperage threshold.
 3. The hydrogen generatingsystem of claim 1 wherein adjusting the applied voltage based on thecomparison comprises applying a maximum voltage if the actual amperageis below the maximum amperage threshold and if the actual temperature isbelow the optimal temperature.
 4. The hydrogen generating system ofclaim 1 wherein the processor is programmed to adjust a duty cycle toenable an average actual amperage to substantially equal the targetamperage if the actual amperage exceeds the maximum amperage threshold.5. The hydrogen generating system of claim 1 wherein the processor isprogrammed to select, based on the target amperage, only a quantity ofthe plurality of conductive plates required to receive an appliedvoltage.
 6. The hydrogen generating system of claim 5 wherein thequantity of the plurality of conductive plates that receive the appliedvoltage is based on at least one of the following: a temperature of anelectrolytic solution, an amount of voltage applied, a distance betweeneach of the plurality of conductive plates, and a type of electrolyticsolution used.
 7. The hydrogen generating system of claim 1 wherein thefirst connector is configured to be an anode or a cathode and the secondconnector is configured to be the other of an anode or a cathode.
 8. Thehydrogen generating system of claim 7 wherein the processor isprogrammed to select whether the first connector is an anode or acathode and select the second connector as the other of an anode orcathode.
 9. A method of controlling a hydrogen generating system havinga plurality of conductive plates comprising: receiving a targetamperage, a maximum amperage threshold, and an optimal temperature;applying a voltage to at least some of the plurality of conductiveplates in the hydrogen generating system; obtaining an actual amperageand an actual temperature of the hydrogen generating system; comparingthe actual amperage to the maximum amperage threshold and the actualtemperature to the optimal temperature; and adjusting at least one ofthe applied voltage and a duty cycle based on the comparison.
 10. Themethod of claim 9 wherein adjusting at least one of the applied voltageand a duty cycle based on the comparison further comprises applying amaximum voltage for one duty cycle if the actual amperage is below themaximum amperage threshold and if the actual temperature is below theoptimal temperature.
 11. The method of claim 9 wherein adjusting atleast one of the applied voltage and a duty cycle based on thecomparison further comprises computing a duty cycle to increase theactual temperature of the hydrogen generating system if the actualamperage exceeds the maximum amperage threshold and if the actualtemperature is below the optimal temperature.
 12. The method of claim 9wherein adjusting at least one of the applied voltage and a duty cyclebased on the comparison further comprises computing a duty cycle if theactual temperature is substantially equal to the optimum temperature.13. The method of claim 9 wherein adjusting at least one of the appliedvoltage and a duty cycle based on the comparison further compriseslowering a duty cycle if the actual temperature does not substantiallyequal the optimal temperature.
 14. The method of claim 9 whereinadjusting at least one of the applied voltage and a duty cycle based onthe comparison further comprises: turning a current of the hydrogengenerating system off if the actual temperature exceeds a maximumtemperature threshold; measuring a second actual temperature; andturning the current of the hydrogen generating system on when the secondactual temperature is below the maximum temperature threshold.
 15. Themethod of claim 9 wherein adjusting at least one of the applied voltageand a duty cycle based on the comparison further comprises turning acurrent of the hydrogen generating system off for a predefined period oftime if the actual amperage exceeds a predefined maximum safe amperagethreshold.
 16. A computer readable medium having instructions recordedthereon that when executed by a processor cause the processor to:receive a target amperage, a maximum amperage threshold, and an optimaltemperature; apply a voltage to at least some of a plurality ofconductive plates in a hydrogen generating system; obtain an actualamperage and an actual temperature of the hydrogen generating system;compare the actual amperage to the maximum amperage threshold and theactual temperature to the optimal temperature; and adjust at least oneof the applied voltage and a duty cycle based on the comparison.
 17. Thecomputer readable media of claim 16 wherein adjusting at least one ofthe applied voltage and a duty cycle based on the comparison furthercomprises applying a maximum voltage for one duty cycle if the actualamperage is below the maximum amperage threshold and if the actualtemperature is below the optimal temperature.
 18. The computer readablemedia of claim 16 wherein adjusting at least one of the applied voltageand a duty cycle based on the comparison further comprises computing aduty cycle to increase the actual temperature of the hydrogen generatingsystem if the actual amperage exceeds the maximum amperage threshold andif the actual temperature is below the optimal temperature.
 19. Thecomputer readable media of claim 16 wherein adjusting at least one ofthe applied voltage and a duty cycle based on the comparison furthercomprises computing a duty cycle if the actual temperature issubstantially equal to the optimum temperature.
 20. The computerreadable media of claim 16 wherein adjusting at least one of the appliedvoltage and a duty cycle based on the comparison further compriseslowering a duty cycle if the actual temperature does not substantiallyequal the optimal temperature.
 21. The computer readable media of claim16 wherein adjusting at least one of the applied voltage and a dutycycle based on the comparison further comprises: turning a current ofthe hydrogen generating system off if the actual temperature exceeds amaximum temperature threshold; measuring a second actual temperature;and turning the current of the hydrogen generating system on when thesecond actual temperature is below the maximum temperature threshold.22. The computer readable media of claim 16 wherein adjusting at leastone of the applied voltage and a duty cycle based on the comparisonfurther comprises turning a current of the hydrogen generating systemoff for a predefined period of time if the actual amperage exceeds apredefined maximum safe amperage threshold.